Nestle Summer Associate
Program-2014
Umar Saeed (Industrial & Manufacturing Engg, UET, Lahore)
Department: Engineering
M. Zubair Amjad Project Engineer
Nestle, SKP-factory
Zeeshan Ameen Senior Project Engineer
Nestle, SKP-factory
LINE Managers:
Acknowledgements:
I dedicate my accomplishments during
this internship to my line managers Mr.
Zubair Amjad & Mr. Zeeshan Ameen.
Their sincere guidance & complete
follow-through supported me to achieve
my tasks in such a short time.
Engineering Dept. overview
Utilities
Maintenance --Boilers
--Refrigeration Equipment
--Electrical Gen. sets
Capital investment
projects -- New Installation of
lines, plant machinery etc.
Utilities Projects -- Installation of boilers,
chillers, compressor
room etc.
Engineering
Department
Projects during Internship:
-- Designed the best possible layout for yogurt plant old blast for the installation of cooling cells, calculating costs and energy savings and calculation of payback period.
-- Formulated a project plan w.r.t. time estimation of sprinklers installation in warehouse 2 & 3 using MS-Project.
-- Calculation of cooling load of Tetra Hall using ACCALC, comparing with A.H.U. capacity before and after installation of ELPO & Prisma line and proposed an optimum solution.
-- Study & optimization of CIP target lines for readjustment to reduce downtime on highly loaded lines & make room for new targets.
-- Planning of activities for dismantling, shifting and installation of Duplex filling from Egron-2 to Egron-1.
1st Project
Objective: Reduction in down time by shuffling
targets.
proposal for adjustment of new targets.
Duration: 24th June - 24th July
Area: Standardization
Study & optimization of CIP target lines for readjustment to reduce
downtime on highly loaded lines & make room for new targets.
Time load on lines
Line 1 12hr 50min
Line 2 7hr 20min
Line 3 10hr 55min
Line 4 10hr 10min
Line 5 9hr
Results: Proposed plan for CIP distribution on
discussion with staff persons and made
CIP distribution diagrams for all existing
lines after addition of new targets.
2nd Project:
Objective: Calculate the cooling load.
Comparison with existing A.H.U.
Provide optimum solution if its under
capacity.
Duration: 30th June - 10th July
Area: Milk Standardization
Calculation of cooling load of Tetra Hall using ACCALC, comparing with
A.H.U. capacity before and after installation of ELPO & Prisma line and
proposed an optimum solution.
Results: Cooling load by ACCALC = 894 kW
A.H.U. Capacity = 888 kW
Difference = 6 kW
Solution: Re-designing of cooling
coil, it’s efficiency can be increased
by 30%.
Summarized data from ACCALC:
Scope Media
AHU Nestlé Star-Rating 3-Star
Coarse filter class G4
Fine filter class F7
Cooling coil yes chilled water 7 °C / 13 °C
(re)heating coil yes steam 3 bar
supply airflow 118,000 m3/h
outside airflow 9,040 m3/h
outside air conditions summer 45.0 degC 85 %rH
return air conditions summer 30.0 degC 50 %rH
supply air conditions summer 19.4 degC 13.7 g/kg
(re)heater temperature in/out 18.2 degC 28.9 degC
3rd Project:
Objective: Layout optimization of Blast Room for
installation of cooling cell.
Calculation of energy & cost savings.
Group Member: Amna Nawaz
Duration: 11th July - 22nd July
Area: Yogurt Plant
Designed the finest layout for yogurt plant old blast for the installation of cooling
cells, calculating costs and energy savings and calculation of payback period.
Exis
tin
g
Pro
po
se
d
4th Project:
Objective: Project planning.
Adjustment of activities with working
movements in warehouse.
Duration: 10th July - 16th July
Area: Warehouse 2 & 3
Formulate a project plan w.r.t. time estimation of fire sprinklers
installation in central warehouse using MS-Project.
Ga
ntt
Ch
art
Result: Time for completion
is 2 months & 10 days
5th Project:
Objective: Turn out the constraint of time during
annual shutdown.
Decision of resources and man hours
Make a project plan.
Duration: 21st July - 5th August
Area: Egron 1 & 2
Study & Planning of activities for dismantling, shifting and
installation of Duplex filling from Egron-2 to Egron-1.
Results: Completion in 9 days before deadline
Man hours = 207
Working days = 27
Summarized Conclusions:
If your project is designed perfectly in the planning phase
and initial stages then, situation go well in your favor.
Don’t hesitate to ask, more you ask less mistakes you
make.
Don’t rely on other’s calculation. Do them yourself.
No one else can be blamed, only you’ll be the responsible
for not meeting your targets.
Other Activities:
Visited MRU and got an overview over whole milk
receiving process and then its initial processing
before pasteurization
Checked the feasibility of replacing THE with PHE & PHE with THE in skp-
factory on basis of discussion with plant
manager
Got summary of the whole yogurt formation
process from raw material in milk form to
final processed product.
Understood the working of filling machine in Tetra
hall from a worker operating that machine.
Visited technical storage and learned about how inventory is managed according to required
demand
Performed Vacuum pressure test on the compressors of the
cooling units in cold blast
Visited “pure life” water plant and got an
overview over whole process of blowing,
filling, packaging etc.
Received an overview over waste water
treatment plant by visiting it and understand the
whole process
Went to see E1 & E2, checked out the process of powder formation & some other technical
information about plant
During discussions, understood the process of P2P that involves the
steps involving from purchase order to
receiving
Made a tour of chillers for chilled water formation and cooling towers and
understood their working
Studied some data relating to Wartsila,
boilers, refrigerating units , A.H.U. etc.
Suggestions on common observation in
Nestle
About Plant
Preventive Maintenance
Proper examination of pipes
insulation
Follow standards using
hook-up plates
Shift to automation as much
as possible
Minimize heat loses in
areas under A.H.U.
About Management
Try to shift towards pull
system from push system
Job rotations & jobs in
accordance to employees
background
Defined areas for persons
with same jobs in office.
Unannounced visits of SHE
and 5’S teams
Suggestions on common observation in
Nestle
About Safety
Proper use of hygiene
cap.
Use of Masks in CIP
tanks room.
Sign boards to direct
towards walking surfaces.
About Associate Program
Try to create a competitive
environment among them.
Allocate depts. according to
area of interest.
Defined projects list by each
line-manager before start of
associate program.
Treat them like permanent
employees.
Special Thanks To:
Ghufranullah Khan Business Support
Executive Engineering dept
Maratib Ali Manufacturing
Specialist STD
Saeed Mughal Shift Engineer Yogurt Plant
Ikram Yousaf
Karam Elahi Team Leader Yogurt Plant
Shakir Hussain Ammonia safety
champion Engineering Dept.
Mohammad Mobashir Project Engineer Engineering Dept.
Asif Siddiqui Draftsman Engineering Dept.
Line-Managers Feedback:
“You are keen to learn, not hesitant to work on sites and possess good
analytical skills but you should need to improve your communication skills and
be confident on your work. I wish you to groom yourself to such an extent of
being stated as a true Muslim and the most demanding employee.”
(M. Zubair Amjad)
“In your interaction and task-orientation with me during projects, I found you
motivated, hardworking and intelligent. Try to avoid pillow talk in your
communications and I wish you to professionally grow to the highest level in
your career.”
(Zeeshan Ameen)